1- A part should be purchased from a single source supplier. Purchasing a part from multiple suppliers can result in a varietyof problems. Which of the following is not a problem caused by multiple suppliers?

A) Variation in quality

B) Loss of volume discounts

C) Poor delivery service

D) Decreased investment in equipment and training

2-Which of the following is associated with backward scheduling?

A) Finite loading

B) Infinite loading

C) Interoperation sequencing

D) Dispatch lists

3-Which of the following is/are needed in order to calculate manufacturing lead-times?

I. Routings

II. Interoperation times

III. Component purchase lead time

A) I and II

B) I and III

C) II and III

D) I, II, and III

4-Which of the following are true regarding operations scheduling?

A) It is a short-range scheduling technique

B) It is a medium-range scheduling technique

C) It is a long-range scheduling technique

D) None of the above

5-Which of the following is affected when input does not match output?

I. Lot sizesII. Lead timesIII. Queue sizes

A) I and II

B) I and III

C) II and III

D) I, II, and III

6- Which of the following best describes back scheduling?

A) Start with the current date and calculate the order due date by the time of each operation

B) Rescheduling jobs where the input is greater than output

C) Starting with the order due date, calculate the start date of the order by going back through each operation

D) Eliminating capacity availability by working back through the operations

7-When orders are assigned to the factory without any restrictions on capacity, this is known as:

A) smoothed capacity load.

B) overloaded.

C) unsmoothed load.

D) lumpy capacity load.

8- own as the:

A) Standard rate.

B) Cycle time.

C) Capacity rate.

D) Setup time

9-complete the job? (Round to the nearest whole day)

Machine = 2

Number of operations = 2

Shis per day = 1

Hours per shi = 8

Machine ul izaon = 90%

Operator efficiency = 90%

A) 6

B) 7

C) 8

D) 9

10- Which of the following best describes the forward scheduling technique?

I. Begins with a known start date and calculates a completion date for an order

II. Dates generated are earliest start dates for each operation

III. Orders are loaded for each operation, first to last

A) I and II

B) I and III

C) II and III

D) I, II, and III

11- Which of the following best defines a gateway work center?

A) The work center which is the bottleneck

B) The work center with the first operation

C) The work center just before the final assembly

D) The work center which is last

12- Which of the following statements are true regarding infinite loading?

I. The technique is valid although the name is misleadingII. The technique is now known as capacity requirements planningIII. It is also known as operations scheduling

A) I and II

B) I and III

C) II and III

D) I, II, and III

13- Which of the following statements are true regarding lead time?

I.

An overloaded factory floor increases lead time.

II.

Lead time will decrease when input equals output.

III.

Lead time will decrease if output exceeds input.

A)

I and II

B)

I and III

C)

II and III

D)

I, II, and III

14- In a manual rescheduling process, which of the following are true?

I. MRP provides information regarding which order to reschedule.II. Planners or other personnel make the changes necessary.III. Scheduled receipts are manually changed.

A) I and II

B) I and III

C) II and III

D) I, II, and III

15- In order to determine the operation duration, which of the following would be included?

I. Setup timeII. Wait timeIII. Run time

A) I and II

B) I and III

C) II and III

D) I, II, and III

15- In a job shop environment, which of the following are true?

I. Less work in process inventory increases lead timesII. Longer queues increase lead timesIII. More work-in-process means increased lead times

A) I and II

B) I and III

C) II and III

D) I, II, and III

17- Using the critical ratio, jobs which are ahead of schedule carry a ratio of:

A) greater than 1.0.

B) less than 1.0.

C) equal to 1.0.

D) None of the above

18- Which of the following will be true if the cumulative lead time of a product is longer than the MPS planning horizon?

A) Orders for long lead time components will be released late.

B) Orders for long lead time components will be released early.

C) Order point can be used for the longest lead time items without affecting priorities.

D) There is no impact.

19- Which of the following statements are generally included in a routing?

I. Operations to be performed and their sequenceII. Work centers involved in manufacturingIII. The raw materials needed to produce

A) I and II

B) I and III

C) II and III

D) I, II, and III

20-

A) a job is ahead of schedule by 25%.

B) a job is ahead of schedule by 75%.

C) a job is behind schedule by 25%.

D) a job is behind schedule by 75%

21- Which of the following are requirements for a shop order release?

I. Parts availabilityII. Order due dateIII. Tooling availability

A) I and II

B) I and III

C) II and III

D) I, II, and III

22-A company makes long runs of parts in a sequence of work centers. Because of this, they start the second operationbefore the job is completed at the first operation. This method of scheduling is called:

A) Lead-time offsetting

B) Overlapped scheduling

C) Capacity overlapping

D) Work center utilization

23-Which of the following best describes mixed model scheduling?

A) A regression analysis to schedule finite capacity

B) A master schedule approach in a make-to- order environment

C) A schedule in which products and lot sizes vary so every model is made every day

D) A database system in which access is user friendly

24- Which of the following will increase machine utilization?

A) Small lot sizes

B) Minimal unplanned downtime

C) Small work in process queues

D) Making frequent product changeovers

25- The term "line balancing" means that the:

A) machines are an equal distance apart.

B) time taken at each work station is equal.

C) high, low, and medium volume work is separated.

D) setup time on each machine is equal.

26- In the electronics manufacturing industry, there is often a process step called bake at the end of the production process.The process steps ahead of the bake step are generally completed faster than the bake step. This bake step is known as a:

A) Clogging operation.

B) backflush operation.

C) Gating operation.

D) Constraint.

27- In process industries, such as in an oil refinery, the primary execution and control concern is:

A) Linearity.

B) Synchronizing the operations.

C) input/output control.

D) Setup times.

28- Producon or der 650 is for 500 of par t 3009. From the roung fil e, it is det er mi ned that the set up me i s 3.0 hour s andthe run me is .25 hour s per pi ece. Wh at is the requi red capaci ty for thi s par t?

A) 120 hours

B) 125 hours

C) 128 hours

D) 132 hours

29- An order for 200 of a product is processed on work centers 101 and 102. The setup me on wo r k cent er 101 is 60

each. The wait me bet we en each oper aon i s 3 hour s and t h e move me bet we en 101 and 102 is 30 mi nut es . The wa i t meae r wo r k cent er 102 is 4 hour s wi th a mo ve me t o s torage of 20 min ut es. Wha t i s the t otal man uf act uri ng l ead me f or t heorder?

A) 28.5 hours

B) 29.3 hours

C) 36.3 hours

D) 39.4 hours

30- Which of the following best describes the term "production activity control"?

A) Demand planning from customers

B) Execution of the material plans

C) Procurement activity

D) Final assembly scheduling

31- Repetitive manufacturing environments are characterized by which of the following?

I. Use of schedules instead of work ordersII. Consistent flow of finished productsIII. Inventory issue transactions used for inventory

A) I and II

B) I and III

C) II and III

D) I, II, and III

32- Which of the following are the result of setup reductions?

I. Increases flexibility in manufacturingII. Reduces lead timesIII. Allows large lot size production

A) I and II

B) I and III

C) II and III

D) I, II, and III

33- Preventive maintenance is important in all companies, but is usually the smallest portion of the maintenance budget. Fora lean manufacturing environment, preventive maintenance is critical for which of the following reasons?

I. Unplanned downtime due to breakdowns is avoided

II. It allows the production line to produce saleable units

III. It extends the useful life of equipment, thereby delaying investment in new equipment

A) I and II

B) I and III

C) II and III

D) I, II, and III

34- A reliable JIT system will not only simplify operations but will also simplify transactional activity in which of the followingareas?

I. PurchasingII. Shop floor trackingIII. Quality control

A) I and II

B) I and III

C) II and III

D) I, II, and III

35- An assembly line has been set up as a flow line. As each component of the final product is attached, the semi finishedassembly is then passed to the next person on the line. This process continues until the final product is completed. There aresix steps in place to complete the assembly. The line works one 10 hour shi per day (assume a 60 minute hour), 5 days perweek. The demand for the product is 1000 per day.

Based on the above information, what is the takt time of the line?

A) .6 minutes

B) 1 minute

C) 1.67 minutes

D) 10 minutes

36- In a plant with a smooth flow of products, which of the following scheduling methods works best?

A) Work order based

B) Repetitive work order

C) Visual/Kanban system

D) Input/output method

37- Many times, companies will implement kanban replenishment and believe they can eliminate all other systems. However,kanban is not a replacement for:

A) priority scheduling.

B) planning.

C) input/output control.

D) capacity requirements planning.

38- When a kanban size has been established, for example 150 units, inventory can be reduced throughout the process by

constraint. At the point a constraint is detected, a continuous improvement project can be undertaken to eliminate theconstraint so lot sizes can be reduced further. In this example of continuous lot size (kanban) reduction, a critical part of thisprocess would be which of the following?

A) Cost reductions

B) Flow improvements

C) Setup reductions

D) Accounting standards

39-In a lean manufacturing environment using kanban methodology, many benefits are generated. Which of the followingwould NOT be a benefit accruing from the use of kanban?

A) 40-70% less floor space

B) Work orders have been eliminated.

C) Labor reporting is eliminated.

D) Less material is stored at the point of use.

40-In a "pull" system environment, the final assembly work center is the driving force for the upstream production. In otherwords, the final assembly work center "pulls" the remaining production through the rest of the work centers. The reason forthis is which of the following?

A) The final assembly work center is closest to the demand.

B) The final quality tests are completed there.

C) The forecast is usually for the finished product.

D) The dispatch list usually does not list the final assembly work center.

41- A manufacturing process which produces families of parts within a single line or grouping of machines where the machineoperators work only in the line or grouping is called:

A) group machining.

B) repetitive manufacturing.

C) cellular manufacturing.

D) process manufacturing.

42- The primary purpose of a dispatch list is to display the:

A) overloaded work centers.

B) priority sequence of manufacturing overload.

C) outbound trucking schedule.

D) inventory amounts by location.

43- Which of the following best describes a focused factory?

A) A plant where all personnel understand the mission and objectives

B) A plant which is established to produce a limited mix of items

C) A plant which has embraced a zero-defect program

D) A plant which concentrates on one job at a time

44- All of the following are true regarding a daily dispatch list EXCEPT:

A) Due dates are taken from MPS

B) Due dates from MRP may be modified

C) It allows the centralization of shop floor control

D) It is generated in priority sequence

45- Which of the following are generally in the shop packet?

I. Operation sheetsII. Pick listsIII. Move tickets

A) I and II

B) I and III

C) II and III

D) I, II, and III

46- A job status report would show:

A) costs accumulated for the job.

B) the input and output of every work center.

C) the plan for completing a job and the progress versus the plan.

D) the job priority at each work center.

47- A job is due 7 work days from today with 7 hours per day available to work on the job. The amount of work left tocomplete the job requires 18 hours. Using the slack me rul e, wh at is the priority on this job?

A) 67

B) 49

C) 31

D) 18

48- The best process for automation is to simplify the work, then automate. When a company does automate with robotics,it is usually:

A) in jobs where imaging is necessary.

B) in highly repetitive jobs not suited for humans.

C) because they cost less than direct labor.

D) to provide a high tech environment.

49- The term "linearity" means:

A) the line capacity is balanced from beginning to end.

B) production is at a constant or level rate.

C) a single source supplies each component.

D) the master schedule is not overloaded.

50- In the Kanban system, lead time reduction is the responsibility of:

A) Supervisors

B) Materials personnel

C) Direct labor personnel

D) Everyone

51-Which of the following time frames are usually associated with subcontracting?

I. Short-RangeII. Medium-RangeIII. Long-Range

A) I and II

B) I and III

C) II and III

D) I, II, and III

52- If a work center is becoming a bottleneck and throughput time is getting longer, which of the following could be asolution?

I. Decrease the inputII. Increase the planned lead timesIII. Increase the capacity

A) I and II

B) I and III

C) II and III

D) I, II, and III

Queson 53, 54,55& 56 Based on Given the following information on a work center:

53-The weekly available capacity at the above work center is: (Rounded to the nearest whole standard hour.)

A) 50

B) 55

C) 58

D) 60

54- If the weekly load on the work center is 72 hours, the work center is:

A) Overloaded

B) Underloaded

C) In balance

D) Not enough data

55- If the hours worked were expanded to a 12 hour shi, wh at wo ul d the avai labl e capaci ty be? (Rounded to t he neareststandard hour.)

A) 60

B) 69

C) 82

D) 96

56- If the work week was expanded to 5 days of 10 hour shis , wh at wo ul d the avai labl e capaci ty be? (Rounded to thenearest standard hour.)

A) 60

B) 72

C) 84

D) 96

57- Which of the following could be causes of idle time?

I. MaintenanceII. SetupIII. Training

A) I and II

B) I and III

C) II and III

D) I, II, and III

58- When a set-up procedure occurs while a machine is not operating, it is called:

A) external setup time.

B) interoperation time.

C) internal setup time.

D) gapped time.

59 -Which of the following statements are true regarding Just-in-Time production?

I. Only refers to the delivery of products when neededII. Refers to the elimination of waste - "If it doesn't add value, it's waste; eliminate it"III. It is a pull system

A) I and II

B) I and III

C) II and III

D) I, II, and III

60- The phrase "one less at a time" refers to which of the following?

A) Reducing the number of suppliers necessary to produce the product

B) The reduction of direct labor caused by the creation of manufacturing cells

C) The process of gradually reducing lot sizes in manufacturing to eliminate obstacles

D) Establishing a flow line in which the production rate is one at a time

61- In a job shop environment, it may not be possible to convert all areas to a "flow" shop. Wherever possible the "flow" canbe accomplished by:

I. Reducing setup times (quick changeover)II. Reducing or eliminating queue timesIII. Lowering defects towards a zero goalIV. Cross-training workers

A) I and III

B) I, II, and III

C) II, III, and IV

D) I, II, III, and IV

62- All of the following are part of starting a Just-in-Time implementation EXCEPT:

A) Conduct some general JIT education

B) Complete a detailed implementation plan for the complete project

C) Pick a pilot project

D) Review pilot project as a learning experiment

63- The process of shutting down a production line or machine upon identification of a defect is:

A) down time.

B) a capacity constraint.

C) simplification.

D) autorotation.

64- An andon is a:

A) work center which constrains the flow.

B) signal system which links work centers.

C) tool for quick set-up.

D) successive fixture.

65- Which of the following would be considered waste in the JIT environment?

I. Purchase ordersII. Factory ordersIII. Receiving documentsIV. Material requisitions

A) I and II

B) II and IV

C) I and IV

D) I, II, III, and IV

66- Which of the following would best describe the term poka-yoke?

A) Mistake proofing a process

B) Setups in less than 10 minutes

C) Lot size equal to one

D) Kanban sizing methodology

67- The concept of deducting component inventory when finished goods are received into stock is commonly referred to as:

A) floor deduction.

B) allocation.

C) material issues.

D) backflushing.

68-There are 4 categories of quality costs. They are prevention, internal failure, appraisal, and external failure. Which of thefollowing would NOT be considered an appraisal cost?

A) Inspection personnel

B) Test equipment in the QC lab

C) Scrap

D) Gauge calibration

69& 70 Based On the Following Information

Period 1 2 3 4 5PLANNED INPUT 150 150 150 150 150ACTUAL INPUT 150 145 130CUMULATIVE DEVIATION 0 -5 -25

Period 1 2 3 4 5PLANNED OUTPUT 180 180 180 180 150ACTUAL OUTPUT 185 140 160CUMULATIVE DEVIATION 5 -35 -55

69- Based on the input/output control chart above, the backlog was reduced by how many hours by Period 3?

A) 30 hours

B) 60 hours

C) 80 hours

D) No reductions

70- Based on the input/output control chart above, what should the input be in Period 4 in order to reduce the backlog?

A) 130

B) 150

C) 160

D) Any of the above

71- Quality is best defined as:

A) zero defects.

B) conformance to requirements.

C) less than .1% tolerance.

D) within range on the SPC chart.

72- The term, "empower", can best be defined by which of the following?

A) The right to hire and terminate personnel

B) Authorize the payment of invoices

C) Enable or give authority

D) Dictate the rules

73- Which of the following are process analysis tools?

I. FlowchartsII. Scatter diagramsIII. GANTT chart

A) I

B) I and II

C) I and III

D) I, II, and III

74-When a quality problem surfaces within a process, the problem can be identified and analyzed using a cause and effectdiagram. This cause and effect analysis is usually made using a:

A) fishbone diagram.

B) SPC chart.

C) force field analysis.

D) Pareto analysis.

75-In order to certify a supplier, a customer will send an audit team to the supplier site to conduct a quality audit on thesupplier. While the audit team members may vary from company to company, which of the following functions would not beincluded in the customer audit team?

A) Buyer

B) Quality engineer

C) Marketing person

D) Materials manager